First Article Inspection Training - NMG Aerospace

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First Article Inspection Reports are to be recorded in English or in a language ... AS9102 A Form 1: Part Number Accountability shall be used to identify the part ...
Guide for successful completion of First Article Inspection Reports

Revision: A Date: May 2014 www.iaqg.org/scmh Section 3.2.4

Introduction

• This presentation is intended as supplemental information in support of the 9102 Standard for Aerospace First Article Inspection requirements.

• This material should be used in conjunction with the standard. The requirements cited in the standard always take precedent.

Requirements • First Article Inspection Reports are to be recorded in English or in a language specified by the customer.

• AS/EN/SJAC9102 Revision A - Aerospace First Article Inspection Requirement

• 8.2.4.2 First Article Inspection: The organization’s system shall provide a process for the inspection, verification, and documentation of a representative item from the first production run of a new part, or following any subsequent change that invalidates the previous first article inspection result. • NOTE: USE (AS) (EN) (SJAC) 9102 with this tutorial for requirements

Requirements

• Additional Customer requirements if applicable • AS/EN/SJAC9102 Rev A forms are to be completed in accordance with the Appendix A guide of the standard

• Note: If alternate forms are used, they must contain all “Required” and “Conditionally Required” information and have the same field reference numbers as AS/EN/SJAC9102 Rev A

Definition FIRST ARTICLE INSPECTION (FAI) A complete, independent, and documented physical and functional inspection process to verify that prescribed production methods have produced an acceptable item as specified by engineering drawings, planning, purchase order, engineering specifications, and/or other applicable design documents. Ref 9102 Rev A

Purpose

• Provides objective evidence: • that all engineering, design and specification requirements, including process and manufacturing validation, are correctly

• • • •

understood accounted for verified and recorded.

• of a consistent documentation requirement for aerospace components.

Evaluation Activities

• The organization should conduct the following activities in support of FAI; • Review documentation for the manufacturing process (e.g., routing sheets, manufacturing/quality plans, manufacturing work instructions, etc.) to make sure all operations are complete as planned.

• Review referenced exhibits supporting the FAI (e.g., inspection data, test data, Acceptance Test Procedures, etc.) for completeness.

• Review nonconformance documentation (if any), for completeness.

• Review material certifications for compliance, as applicable.

Evaluation Activities • Verify that approved Special Process sources are used (as applicable), and that the manufacturing planning/routing document calls out the correct specification.

• Verify that Key Characteristic requirements have been met, as applicable Verify part specific gages and/or tooling are qualified and traceable, as applicable.

• Verify that every design characteristic requirement is accounted for, uniquely identified and has inspection results traceable to each unique identifier.

• Note the company FAI procedure should address all evaluation activities

When should FAI be performed?

• Full FAI • • • •

New part introduction New supplier or new location of manufacture Lapse in production for more than 2 years When required by the customer

• Partial (Delta) FAI • Design change • A change in the method of manufacture (e.g. Tooling, Processes, Machine, Location, Numerical Control Program, Sequence of Manufacture).

What does it apply to?

• All product defined by engineering drawings or model based definitions. Delete-issued by the Customer

• Assemblies- for those characteristics specified on the assembly level drawing only

• All levels of detail parts within assembly • including castings and forgings • Modified Standard, Electronic or COTS Items as “make from” with unique engineer modifications on drawing

• Only the modifications

What does it apply to?

• Standard Parts • Electronic Components • Commercial Off The Shelf (COTS) Items No FAI required

What is included?

• Verification of all design characteristics • Material and Special Process Certifications • Manufacturing Process Verification • Nonconformance resolution

Forms The Following Forms comprise a First Article Inspection Report (FAIR) full instructions in 9102 appendix A • AS9102 A Form 1: Part Number Accountability shall be used to identify the part that is being first article inspected (FAI part) and associated sub-assemblies or detail parts. • AS9102 A Form 2: Product Accountability – Raw Material, Specifications and Special Process(s), Functional Testing shall be used if any material, special processes or functional testing are defined as a design requirement. • AS9102 A Form 3: Characteristic Accountability, Verification and Compatibility Evaluation shall be used to record an actual measurement or inspection/verification of the FAI part for every design characteristic on the drawing, including notes.

AS9102 A Form 1 – Part Number Accountability 1. Part Number

2. Part Name

3. Serial Number

4. FAI Report Number

5. Part Revision Level

6. Drawing Number

7. Drawing revision level

8. Additional Changes

9. Manufacturing Process Reference

10. Organization Name

11. Supplier Code

12. P.O. Number

13. Detail FAI

14.

Baseline Part Number including revision level

Assembly FAI a) b)

Full FAI Partial FAI Reason for Partial FAI:

if above part number is a detail part only, go to Field 19 if above part number is an assembly, go to the “INDEX” section below.

INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. 15. Part Number

16. Part Name

17. Part Serial Number

18. FAI Report Number

YELLOW or LIGHT GREY fields – MANDATORY information required. BLUE or DARK GREY fields – CONDITIONALLY REQUIRED. These fields must be completed when information is available. WHITE fields – OPTIONAL information required when available. 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 2) Also indicate if the FAI is complete per Section 5.4: 19. Signature By

FAI complete

FAI not Complete 20. Date

21. Reviewed By

22. Date

23. Customer Approval

24. Date

Form 1, 9102 Rev A, Date: Oct 24, 2003

AS9102 A Form 1 – Part Number Accountability 1. Part Number

2. Part Name

3. Serial Number

4. FAI Report Number

5. Part Revision Level

6. Drawing Number

7. Drawing revision level

8. Additional Changes

Box 1. Part Number of the FAI part. Box 2. Name of the part as shown on the drawing. 9. Manufacturing Process Box Reference

10. Organization Name

11. Supplier Code

12. P.O. Number

3. Serial number of the FAI part.

Box 4. The Report No. 13. Detail FAI

Box 5. The revision of Assembly FAI there is no revision.

14. Full FAI Baseline Part Number including revision level Partial FAI being first article inspected. the part

Indicate if

Reason for Partial FAI: Note: The latest revision (Box 7) does not always affect all parts contained on a drawing. a) if above part number is a detail part only, go to Field 19 b) ifThe above partdrawing number is an assembly,number go to the “INDEX” section below. Box 6. associated with the FAI part.

INDEXfrom of part numbers or sub-assembly numbers required to make the assembly noted above. (if different part number) 15. Part Number

16. Part Name

17. Part Serial Number

18. FAI Report Number

Box 7. Reference the revision engineering drawing. (if drawing number is different from part number)

Box 8. Reference Design, Engineering or Manufacturing changes affecting the FAI part, not reflected by the current part/drawing 15 revision level.

AS9102 A Form 1 – Part Number Accountability

1. Part Number

2. Part Name

3. Serial Number

4. FAI Report Number

5. Part Revision Level

6. Drawing Number

7. Drawing revision level

8. Additional Changes

9. Manufacturing Process Reference

10. Organization Name

11. Supplier Code

12. P.O. Number

Box 9. Reference the internal works order. 14. Full FAI Baseline Part Number including revision level Box 10. Name ofPartial the FAI organization performing the FAI . Assembly Reason for Partial BoxFAI11. Reference theFAI:supplier vendor code. Boxa) 12. Reference the customer Purchase Order number. if above part number is a detail part only, go to Field 19 13. Detail FAI

b) if above part number is an assembly, go to the “INDEX” section below.

Box 13. Check as appropriate. INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. Box 14. as appropriate. For 15. PartCheck Number 16. Part Name 17. Part Partial Serial Number FAI18.provide FAI Report Number the baseline drawing number, including issue status and the reason. i.e Change of manufacturing location, Non-Conformance, Process change, Design change etc.

AS9102 A Form 1 – Part Number Accountability 1. Part Number

2. Part Name

3. Serial Number

4. FAI Report Number

5. Part Revision Level

6. Drawing Number

7. Drawing revision level

8. Additional Changes

Boxes 15, 16, 17 and 18 – this section is only required if the Part Number in Box 1. is an Assembly lower 10. Organization Name level 11. parts. Supplier Code 9. Manufacturing Process with 12. P.O. Number Reference

Box 15. Reference all lower level parts or next level sub-assembly Part Number. 13. Detail FAI

Box 16. Part Assembly FAI

14. Full FAI Partialshown FAI name as

Baseline Part Number including revision level

on the drawing/ parts list.

Reason for Partial FAI:

a) if above part number is a detail part only, go to Field 19 b) if above part number is an assembly, go to the “INDEX” section below.

INDEX of part numbers or sub-assembly numbers required to make the assembly noted above. 15. Part Number

16. Part Name

17. Part Serial Number

18. FAI Report Number

Box 17. Reference the serial number of the part. Box 18. A reference number that identifies the FAI package.

AS9102 A Form 1 – Part Number Accountability

Box 19. The name and signature of the person who prepared the FAI. Box 20. Date when the FAI was prepared. Box 21. The name of the person who reviewed or approved the FAI package. Box 22. Date when the FAI was reviewed. 1) Signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 2) Also indicate if the FAI is complete per Section 5.4: 19. Signature By

FAI complete

FAI not Complete 20. Date

21. Reviewed By

22. Date

23. Customer Approval

24. Date

Form 1, 9102 Rev A, Date: Oct 24, 2003

Box 23. Customer Approval. Box 24. Date of Customer approval.

AS9102 A Form 2 – Product Accountability 1. Part Number

2 Part Name

5. Material or Process Name

6. Specification Number

3. Serial Number

7. Code

8. Special Process Supplier Code

4. FAI Report Number

9. Customer Approval Verification (Yes/No/NA)

10. Certificate of Conformance number

Boxes 1 - 4 are repeated on all forms for convenience and traceability.

11. Functional Test Procedure Number

12. Acceptance report number, if applicable

13. Comments 14. Prepared By

15. Date

AS9102 A Form 2 – Product Accountability 1. Part Number

2 Part Name

5. Material or Process Name

6. Specification Number

3. Serial Number

7. Code

8. Special Process Supplier Code

4. FAI Report Number

9. Customer Approval Verification (Yes/No/NA)

10. Certificate of Conformance number

Box 5. Enter the name of the material or process i.e. Aluminium Alloy, Cadmium Plate etc. Box 6. Enter the material or process specification number, class and material form i.e. AMS4928 Bar (Include ‘make from’ materials, weld/ braze filler materials, standard catalogue hardware etc). Box 7. Reference any material code specified. Box 8. Reference Special Process Supplier Vendor code, name & address. Box 9. Indicate if technical approval is required by the customer. Box 10. Reference Certificate of Conformance number(s) e.g. Special Process, Raw material & Mill certifications, Laboratory Reports etc.

AS9102 A Form 2 – Product Accountability

11. Functional Test Procedure Number

12. Acceptance report number, if applicable

Box 11. Reference the Functional Test procedure as stated on the drawing. Box 12. Reference the Functional Test report. 13. Comments 14. Prepared By

15. Date

Box 13. Comments – As applicable. Box 14. The name of the person who prepared this form. Box 15. Date when this form was completed.

Ballooned Drawings

• A ballooned drawing is optional and considered an industry best practice to support Box 5 of Form 3

• Identify 100% of characteristics • Balloon and number all dimensions • Balloon and number all surface finish callouts • Including exclusion and inclusion area callouts

• Balloon and number all material and hardness callouts • Don’t forget the requirements identified in the title boxes at the bottom of the drawings.

Note 2

Ballooned Drawings

1

2 3

8

4 7

5 6

Note: In this example not all characteristics ballooned

AS9102 A Form 3– Characteristic Accountability, Verification and Compatability Evaluation 1. Part Number

2. Part Name Characteristic Accountability

5. 6. 7. Characteristic 8. Char Reference Designator Requirement No. Location

3. Serial Number Inspection / Test Results

9. Results

10. Designed Tooling

O 14. 11. Non[Insert columns, etc., as required by Conformance Organization or Customer} Number

Boxes 1 - 4 are repeated on all forms for convenience and traceability.

The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 12. Prepared By

4. FAI Report

13. Date

AS9102 A Form 3– Characteristic Accountability, Verification and Compatability Evaluation 1. Part Number 2. Part Name Characteristic Accountability 5. 6. 7. Characteristic 8. Char Reference Designator Requirement No. Location

3. Serial Number

Inspection / Test Results 9. Results

10. Designed Tooling

Opt 14. 11. {Insert columns, etc. as required by Organization NonConformance or Customer} Number

Box 5. Assign a unique number for each design Box 6. Reference the drawing zone Box 7. Reference any zoned characteristics i.e. Key characteristic. (include Sheet No. and Zone). Characteristics, Critical Characteristic, etc. These are to be Safety traceable to each drawing requirement.

The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 12. Prepared By

4. FAI Report

13. Date

AS9102 A Form 3– Characteristic Accountability, Verification and Compatability Evaluation 1. Part Number

2. Part Name Characteristic Accountability

5. 6. 7. Characteristic 8. Char Reference Designator Requirement No. Location

3. Serial Number

4. FAI Report

Inspection / Test Results 9. Results

10. Designed Tooling

O 14. 11. {Insert columns, etc. as required by Organizatio NonConformance or Customer} Number

Box 9. Box 10. Record the tool identification number of specially Indicate measurements obtained for each design characteristic. Boxdesigned 8. Indicate the specified requirement for the design tooling used as alisted media ofindividual inspection. Multiple characteristics shall be as values. Box 11. Recordi.e. non-conformance document number if any characteristic Dimensional features with reference minimum and Box 14. Record any is addition information required. Alldesign drawing notes must be accounted for. characteristic found non-conforming. maximum value of tolerance, Drawing notes, Specification requirements etc. Processes that require design verification must have statement of compliance recorded on the form i.e. Certification of Compliance – state ‘Accept’. Laboratory reports or Certificate of test must show specific values for requirements and actual results. The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 12. Prepared By

13. Date

AS9102 A Form 3– Characteristic Accountability, Verification and Compatability Evaluation 1. Part Number

2. Part Name Characteristic Accountability

5. 6. 7. Characteristic 8. Char Reference Designator Requirement No. Location

3. Serial Number Inspection / Test Results

9. Results

10. Designed Tooling

Opt 11. 14. [Insert columns, etc., as required by Organization NonConformance or Customer] Number

Box 12. Name of the person who prepared this form. Box 13. Date when this form was completed.

The signature indicates that all characteristics are accounted for; meet drawing requirements or are properly documented for disposition. 12. Prepared By

4. FAI Report

13. Date

Forms Link AS9102 A forms can be downloaded at: www.sae.org/aaqg/publications/as9102a-faq.htm

9102 FAQ Link www.sae.org/iaqg/publications/faq9102.htm

Most Common Reasons for FAI Rejection

• C of Cs do not accompany the FAI Report. • Missing FAI Reports or Test Reports for sub-assemblies • • • • •

and/or fabricated detail parts. Variable data requirements from the engineering drawing are not provided with numerical results. Missing or wrong information provided. Missing special processor full address on AS9102 A Form 2, box 8. Missing tolerances on AS9102 A Form 3, box 8. Customer flow down requirements not met.

Contact

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